Fiber-reinforced plastic and production method therefor

ABSTRACT

A production method for fiber-reinforced plastic, includes: a step in which a material (A) including a prepreg base material is obtained, said prepreg base material having cuts therein and having a thermoplastic resin impregnated in reinforcing fibers arranged in parallel in one direction; a step in which a pressurizing device is used that applies a substantially uniform pressure in a direction (X) orthogonal to the travel direction of the material (A) and the material (A) is caused to travel in the one direction and is pressurized while being heated to a prescribed temperature (T), an angle (θ) of −20° to 20° being formed between the orthogonal direction (X) and a fiber axial direction (Y) for the reinforcing fibers of the prepreg base material; and a step in which the material (A) pressurized by the pressurizing device is cooled and the fiber-reinforced plastic is obtained.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of U.S. patentapplication Ser. No. 15/117,132, which is a national stage ofInternational Application No. PCT/JP2015/054011, filed Feb. 13, 2015,which claims priority to Japanese Patent Application No. 2014-026641,filed Feb. 14, 2014. The contents of these applications are incorporatedherein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a fiber-reinforced plastic and a methodfor producing the same.

The present application claims priority based on Japanese PatentApplication No. 2014-026641, filed in Japan on Feb. 14, 2014, thedisclosure of which is incorporated herein by reference.

BACKGROUND ART

In various fields related to aircraft members, automotive members, windpower generating windmill members, sports goods and the like, structuralmaterials that have been shaped by stamping molding sheet-likefiber-reinforced plastics are widely used. Such a fiber-reinforcedplastic is formed by, for example, laminating plural sheets of a prepregsubstrate that is obtained by impregnating reinforcing fibers with athermoplastic resin, and integrating the laminate.

An example of the prepreg substrate is a product obtained byunidirectionally arranging continuous reinforcing fibers with a longfiber length in parallel, impregnating the arranged fibers with athermoplastic resin, and forming the resultant into a sheet form. When afiber-reinforced plastic formed from a prepreg substrate using suchcontinuous long reinforcing fibers is used, a structural material havingexcellent mechanical properties can be produced. However, in thisfiber-reinforced plastic, since continuous reinforcing fibers are used,fluidity at the time of shaping is low, and it is difficult to shape thefiber-reinforcing plastic into a complicated shape such as athree-dimensional shape. Therefore, in a case in which thefiber-reinforced plastic is used, the shape of the structural materialthus produced is limited mainly to those shapes close to a planar shape.

Regarding the method for increasing fluidity at the time of shaping, forexample, a method of cutting out plural prepreg pieces from a tape-likeprepreg substrate having a narrow width into a constant length,dispersing the prepreg pieces in a planar form, integrating the prepregpieces by press molding, and thus obtaining a sheet-likefiber-reinforced plastic, has been disclosed (Patent Document 1).

However, in this method, since the prepreg pieces are dispersed bycausing prepreg pieces to fly by means of air or by spreading prepregpieces in a liquid fluid and settling the prepreg pieces, it is verydifficult to disperse the prepreg pieces uniformly such that the fiberaxis directions of the reinforcing fibers are in completely randomdirections. Therefore, a fiber-reinforced plastic is obtained, in whichmechanical properties such as strength vary depending on the position ordirection even within the same sheet. In regard to structural materials,there is a high demand for materials in which there is less variation inthe mechanical properties such as strength, and the mechanicalproperties are isotropic, or anisotropies thereof are under control.However, in this method, it is difficult to obtain a fiber-reinforcedplastic in which mechanical properties are satisfactorily isotropic, oranisotropies thereof are under control, and there is less variation inthe mechanical properties.

In addition, satisfactory heat resistance is also required fromfiber-reinforced plastics. Generally, the heat resistance of afiber-reinforced plastic is greatly affected by the heat resistance ofthe matrix resin used in the fiber-reinforced plastic. Typically,mechanical properties of a simple resin substance tend to deteriorate ata temperature higher than or equal to the glass transition temperatureof the resin. Similarly, in the case of a fiber-reinforced plastic,mechanical properties tend to deteriorate at a temperature higher thanor equal to the glass transition temperature of the matrix resin. Inorder to suppress this deterioration of mechanical properties to aminimum level, it is necessary to uniformly disperse reinforcing fibersin the matrix resin in the fiber-reinforced plastic. However, accordingto the method described above, in the process for integrating depositedprepreg pieces by heating, only molten matrix resin flows into the gapsbetween the deposited prepreg pieces. Therefore, in the fiber-reinforcedplastic thus obtained, locally resin-rich portions are generated. Due tothe effect of these resin-rich portions, a fiber-reinforced plasticobtainable by this method has a problem of inferior heat resistance.

Methods in which plural sheets of a prepreg substrate obtained byimpregnating reinforcing fibers that are unidirectionally arranged inparallel with a thermoplastic resin and forming slits therein such thatthe slits intersect the fiber axes, are laminated and integrated toobtain a fiber-reinforced plastic, have also been disclosed (PatentDocuments 2 to 6). In a fiber-reinforced plastic obtainable by thismethod, since slits are formed in the prepreg substrate and split thereinforcing fibers, satisfactory fluidity may be obtained at the time ofshaping. Furthermore, when plural sheets of a prepreg substrate arelaminated such that the fiber axial directions of the reinforcing fibersare not biased in a particular direction, for example, such that thefiber axial directions are shifted by 45° each when viewed in a planarview, a fiber-reinforced plastic having mechanical properties that aresatisfactorily isotropic and have less variation can be obtained.Furthermore, anisotropy can be controlled by aligning the fiber axialdirections in an arbitrary direction and laminating the plural sheets ofprepreg substrate.

However, a fiber-reinforced plastic obtainable by this method has aproblem that in a case in which stress occurs in a direction thatfollows the slit shape, these slit parts serve as the starting points ofbreakage, and mechanical properties deteriorate. Furthermore, sincesubstantially only the resin exists in these slit parts, at atemperature higher than or equal to the glass transition temperature ofthe matrix resin, the fiber-reinforced plastic has a problem of inferiorheat resistance, similarly to the method disclosed in Patent Document 1.

Furthermore, in this method, in a case in which a band-shapedfiber-reinforced plastic having satisfactorily isotropic mechanicalproperties is continuously produced, it is necessary to separatelyproduce band-shaped prepreg substrates having fiber axial directions ofthe reinforcing fibers that are different from each other when viewed ina planar view (for example, 0°, 45°, 90°, and −45° with respect to thelength direction), and to laminate those prepreg substrates. Therefore,the production process becomes complicated, with difficulty in control,and the production cost increases. Furthermore, even in a case in whichsheets of a fiber-reinforced plastic are produced, the sheets need to belaminated while the respective prepreg substrate sheets are frequentlyrotated at predetermined angles of rotation (0°, 45°, 90°, and −45°) sothat the fiber axial directions of the reinforcing fibers are not biasedwhen viewed in a planar view. Therefore, similarly in this case, thelamination operation becomes complicated, with difficulty in control,and the production cost increases.

Patent Document 7 discloses a method for producing a fiber-reinforcedplastic by dispersing reinforcing fibers by a papermaking process. In afiber-reinforced plastic obtainable by this method, since thereinforcing fibers are almost uniformly dispersed, the fiber-reinforcedplastic has excellent isotropic mechanical properties with lessvariation, and also has satisfactory heat resistance.

However, in a fiber-reinforced plastic obtainable by this method, sincethe reinforcing fibers are three-dimensionally entangled, fluidity atthe time of shaping is very poor. Furthermore, the production process isalso very complicated, and is markedly disadvantageous in terms of cost.In addition, in a case in which it is attempted to produce afiber-reinforced plastic having a high percentage content of reinforcingfibers by this method, it is necessary to perform papermaking in a statein which the reinforcing fibers are more densely incorporated. However,when it is intended to impregnate reinforcing fibers that are subjectedto papermaking at a high density as such with a matrix resin, sincereinforcing fibers that are oriented in the thickness direction(direction of impregnation) in particular, among the reinforcing fibersthat are three-dimensionally entangled, cope with the stress of thepressing force at the time of impregnation, pressure is not transferredto the resin, and it is very difficult to achieve impregnation.Furthermore, even in a case in which the fiber length of the reinforcingfibers is long, since three-dimensional entanglement becomes strong,similarly impregnation becomes difficult.

CITATION LIST Patent Document

-   Patent Document 1: JP 07-164439 A-   Patent Document 2: JP 63-247012 A-   Patent Document 3: JP 63-267523 A-   Patent Document 4: JP 2008-207544 A-   Patent Document 5: JP 2008-207545 A-   Patent Document 6: JP 2009-286817 A-   Patent Document 7: WO 2010/013645 A

SUMMARY OF THE INVENTION Problem to be Solved by the Invention

It is an object of the present invention to provide a fiber-reinforcedplastic which exhibits controllable isotropy or anisotropy in themechanical properties, has excellent mechanical characteristics withless variation, excellent heat resistance, and satisfactory fluidity atthe time of shaping. Furthermore, it is another object of the inventionto provide a method for producing a fiber-reinforced plastic, by whichthe fiber-reinforced plastic can be produced conveniently at low cost.

Means for Solving Problem

The inventors of the present invention conducted a thoroughinvestigation in order to solve the problems described above, and as aresult, the inventors found that the present invention can be solved bythe following items (1) to (15), thus solving the present invention.

(1) A method for producing a fiber-reinforced plastic, the methodincluding the following Steps (i) to (iii):

(i) a step of obtaining material (A) including a prepreg substrate inwhich reinforcing fibers that are unidirectionally arranged in parallelare impregnated with a matrix resin, and slits are formed so as tointersect the fiber axes;

(ii) a step of pressing material (A) using a pressing apparatus thatapplies pressure approximately uniformly in a direction orthogonal tothe travel direction of the material (A), while causing the material (A)to travel in one direction, with the angles θ formed by the fiber axialdirections of the reinforcing fibers of the prepreg substrate withrespect to the above-mentioned orthogonal direction being adjusted to−20° to 20°, in a state in which the material (A) is heated to atemperature T that is higher than or equal to the melting point of thematrix resin, or is higher than or equal to the glass transitiontemperature if the matrix resin does not have a melting point; and

(iii) a step of cooling the material (A) that has been pressed by thepressing apparatus, and thereby obtaining a fiber-reinforced plastic.

(2) The method for producing a fiber-reinforced plastic according to(1), wherein Step (ii) described above is the following Step (ii-1):

(ii-1) a step of pressing the material (A) in a state of being heated tothe temperature T, while causing the material (A) to travel in onedirection, using a pressing apparatus which includes at least a pair ofpress rolls, with the shaft line direction of the rolls forming theorthogonal direction described above.

(3) The method for producing a fiber-reinforced plastic according to(2), wherein heating rolls are used as the press rolls in the Step(ii-1).

(4) The method for producing a fiber-reinforced plastic according to anyone of (1) to (3), wherein the angles θ are adjusted to −5° to 5°.

(5) The method for producing a fiber-reinforced plastic according to anyone of (1) to (4), wherein the thickness of the prepreg laminate is 0.25mm to 6.0 mm.

(6) The method for producing a fiber-reinforced plastic according to anyone of (1) to (5), wherein the matrix resin is a thermoplastic resin.

(7) The method for producing a fiber-reinforced plastic according to anyone of (1) to (5), wherein the matrix resin includes at least oneselected from the group consisting of a polyolefin resin, a modifiedpolypropylene resin, a polyamide resin, and a polycarbonate resin.

(8) The method for producing a fiber-reinforced plastic according to anyone of (1) to (7) wherein the length L of the reinforcing fibers cut bythe slits in the prepreg substrate is 1 mm to 100 mm.

(9) The method for producing a fiber-reinforced plastic according to anyone of (2) to (8), wherein in the Step (ii-1), a double belt-type heatpress machine by which the material (A) is interposed between at leastone pair of belts and is heated while the material (A) is caused totravel so as to pass through between at least one pair of press rolls,and the material (A) is pressed by the at least one pair of press rolls,is used.

(10) A fiber-reinforced plastic including carbon fibers and a matrixresin, in which the fiber length of the carbon fibers is 1 mm to 100 mm,the degree of orientation pf of the carbon fibers in a directionorthogonally intersecting the thickness direction is 0.001 to 0.8, andthe eccentricity coefficient ec of the orientation profile of the carbonfibers in a plane orthogonally intersecting the thickness direction is1×10⁻⁵ to 9×10⁻⁵.

(11) The fiber-reinforced plastic according to (10), wherein thedispersion parameter dp of the carbon fibers in a cross-section in thethickness direction is 100 to 80.

(12) The fiber-reinforced plastic according to (10) or (11), wherein thematrix resin is formed from a thermoplastic resin.

(13) The fiber-reinforced plastic according to any one of (10) to (12),wherein the fiber volume percentage content of the carbon fibers is 5%to 70% by volume.

(14) The fiber-reinforced plastic according to any one of (10) to (13),wherein the fiber length of the carbon fibers is 10 mm to 50 mm.

(15) The fiber-reinforced plastic according to any one of (10) to (14),wherein the thickness of the carbon fiber-reinforced plastic is 0.25 mmto 6.0 mm.

Effect of the Invention

The fiber-reinforced plastic of the present invention exhibitscontrollable isotropy or anisotropy in the mechanical properties, hasexcellent mechanical characteristics with less variation, has excellentheat resistance, and also has satisfactory fluidity at the time ofshaping.

According to the method for producing a fiber-reinforced plastic of thepresent invention, a fiber-reinforced plastic which exhibitscontrollable isotropy or anisotropy in the mechanical characteristics,has excellent mechanical characteristics with less variation, hasexcellent heat resistance, and has satisfactory fluidity at the time ofshaping, can be produced conveniently at low cost.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view diagram illustrating the operation ofpressing material (A) with a pair of press rolls.

FIG. 2 is a schematic diagram illustrating an example of a doublebelt-type heat press machine.

FIG. 3 is a schematic diagram illustrating a process for a method formeasuring the degree of orientation pf.

FIG. 4 is a schematic diagram explaining the processing carried outusing an image processing software program for calculation of thedispersion parameter dp.

MODE(S) FOR CARRYING OUT THE INVENTION

According to the present specification, the angle θ formed by the fiberaxial direction of a reinforcing fiber of the prepreg substrate withrespect to the travel direction of the material (A), is the angle formedby a direction orthogonal to the travel direction of the material (A)when the relevant material (A) is pressed while being caused to travelin Step (ii), as well as the fiber axial direction of a reinforcingfiber of the prepreg substrate in the relevant material (A). In regardto the angle θ, an angle resulting from counterclockwise rotation whenthe material (A) is viewed from the above is considered to have apositive value, and an angle resulting from clockwise rotation isconsidered to have a negative value.

In a case in which a pressing apparatus equipped with at least a pair ofpress rolls, the shaft line direction of rolls being coincident with adirection orthogonal to the travel direction of the material (A), isused as the pressing apparatus in Step (ii), the angle θ is coincidentwith the angle formed by the shaft line direction of the press rolls andthe fiber axial direction of reinforcing fibers of the prepreg substratein the material (A).

<Method for Producing Fiber-Reinforced Plastic>

The method for producing a fiber-reinforced plastic of the presentinvention is a method including the following Steps (i) to (iii):

(i) a step of obtaining material (A) including a prepreg substrate inwhich reinforcing fibers that are unidirectionally arranged in parallelare impregnated with a matrix resin, and slits are formed so as tointersect the fiber axes;

(ii) a step of pressing the material (A) using a pressing apparatus thatapproximately uniformly presses the material (A) in a directionorthogonal to the travel direction of the material (A), while causingthe material (A) to travel in one direction, with the angles θ formed bythe fiber axial directions of the reinforcing fibers of the prepregsubstrate with respect to the orthogonal direction being adjusted to−20° to 20°, in a state in which the material (A) is heated to atemperature T that is higher than or equal to the melting point of thematrix resin, or is higher than or equal to the glass transitiontemperature if the matrix resin does not have a melting point; and

(iii) a step of cooling the material (A) that has been pressed by thepressing apparatus, and thereby obtaining a fiber-reinforced plastic.

[Step (i)]

In Step (i), material (A) that includes a prepreg substrate is obtained.Material (A) may be a single layer material formed from one sheet of aprepreg substrate only, or may be a prepreg laminate obtained bylaminating two or more sheets of a prepreg substrate.

(Prepreg Substrate)

The prepreg substrate used in Step (i) is a product in which reinforcingfibers that are unidirectionally arranged in parallel are impregnatedwith a matrix resin.

The reinforcing fibers are not particularly limited, and for example,inorganic fibers, organic fibers, metal fibers, or reinforcing fibershaving a hybrid configuration of combining the foregoing fibers can beused.

Examples of the inorganic fibers include carbon fibers, graphite fibers,silicon carbide fibers, alumina fibers, tungsten carbide fibers, boronfibers, and glass fibers. Examples of the organic fibers include aramidfibers, high density polyethylene fibers, other general nylon fibers,and polyester fibers. Examples of the metal fibers include fibers ofstainless steel and iron, and carbon fibers coated with metals may alsobe used. Among these, when mechanical properties such as strength of thestructural material as a final molded product are considered, carbonfibers are preferred.

The carbon fibers are not particularly limited, and examples thereofinclude polyacrylonitrile (PAN)-based carbon fibers and PICH-basedcarbon fibers.

Preferred carbon fibers are carbon fibers having a strand tensilestrength of from 1.0 GPa to 9.0 GPa as measured according to JIS R7601(1986) and a strand tensile modulus of from 150 GPa to 1,000 GPa.

More preferred carbon fibers are carbon fibers having a strand tensilestrength of from 1.5 GPa to 9.0 GPa as measured according to JIS R7601(1986) and a strand tensile modulus of from 200 GPa to 1,000 GPa.

The average fiber diameter of the reinforcing fibers is preferably 1 μmto 50 μm, and more preferably 5 μm to 20 μm.

The matrix resin may be a thermoplastic resin, or may be a thermosettingresin. Regarding the matrix resin, one kind may be used alone, or two ormore kinds may be used in combination.

The matrix resin is preferably a thermoplastic resin. Sincethermoplastic resins generally having higher toughness values thanthermosetting resins, when a prepreg substrate impregnated with athermoplastic resin as the matrix resin is used, a structural materialhaving excellent strength, particularly excellent impact resistance, iseasily obtained. Furthermore, in regard to thermoplastic resins, sincethe shape is determined by cooling solidification without beingaccompanied by a chemical reaction, in the case of using the relevantprepreg substrate, molding can be achieved in a short time period, andexcellent productivity is obtained.

The thermoplastic resin is not particularly limited, and examplesthereof include a polyamide resin (nylon 6 (melting point: 220° C.),nylon 66 (melting point: 260° C.), nylon 12 (melting point: 175° C.),nylon MXD6 (melting point: 237° C.), or the like), a polyolefin resin(low density polyethylene (melting point: 95° C. to 130° C.), highdensity polyethylene (melting point: 120° C. to 140° C.), polypropylene(melting point: 168° C.), or the like), a modified polyolefin resin(modified polypropylene resin (melting point: 160° C. to 165° C.), orthe like), a polyester resin (polyethylene terephthalate, polybutyleneterephthalate, or the like), a polycarbonate resin (glass transitiontemperature: 145° C.), a polyamideimide resin, a polyphenylene oxideresin, a polysulfone resin, a polyether sulfone resin, a polyether etherketone resin, a polyetherimide resin, a polystyrene resin, an ABS resin,a polyphenylene sulfide resin, a liquid crystal polyester resin, acopolymer of acrylonitrile and styrene, and a copolymer of nylon 6 andnylon 66.

Examples of the modified polyolefin resin include resins obtained bymodifying polyolefin resins with acids such as maleic acid.

The thermoplastic resins may be used singly or in combination of two ormore kinds thereof.

It is preferable that the thermoplastic resin includes at least oneselected from the group consisting of a polyolefin resin, a modifiedpolypropylene resin, a polyamide resin, and a polycarbonate resin, fromthe viewpoint of the balance between adhesiveness of the reinforcingfibers, impregnability into the reinforcing fibers, and the raw materialcost of the thermoplastic resin.

The thermosetting resin is not particularly limited, and examplesthereof include an epoxy resin, a phenolic resin, an unsaturatedpolyester resin, a urethane-based resin, a ureal resin, a melamineresin, and an imide-based resin.

The thermosetting resins may be used singly or in combination of two ormore kinds thereof.

The thermosetting resin is preferably an epoxy resin, a phenolic resin,an unsaturated polyester resin, or an imide-based resin from theviewpoint of the manifestability of mechanical characteristics of thefiber-reinforced plastic after the thermosetting resin is cured, and thethermosetting resin is more preferably an epoxy resin or an unsaturatedpolyester resin from the viewpoint of the ease of production of theprepreg substrate.

In the prepreg substrate, additives such as a flame retardant, a weatherresistance improving agent, an antioxidant, a thermal stabilizer, anultraviolet absorber, a plasticizer, a lubricating agent, a colorant, acompatibilizer, and an electroconductive filler may be includedaccording to the required characteristics of the intended structuralmaterial.

Furthermore, in the prepreg substrate used in Step (i), slits are formedso as to intersect the fiber axes. Thereby, the relevant prepregsubstrate is in a state in which reinforcing fibers having a long fiberlength, which are unidirectionally arranged in parallel, are split bythe slits.

Generally, as the reinforcing fibers are longer, a structural materialhaving superior mechanical properties is obtained; however, sincefluidity is decreased particularly at the time of stamping molding, itbecomes difficult to obtain a structural material having a complicatedthree-dimensional shape. In the present invention, since the reinforcingfibers are cut and shortened by inserting slits into the prepregsubstrate, the reinforcing fibers and the matrix resin may easily floweven at the time of stamping molding. Therefore, it is also easy toobtain a structural material having a complicated three-dimensionalshape such as a rib or a boss.

Furthermore, when a sheet-like fiber-reinforced plastic is formed bydispersing prepreg pieces cut out from a prepreg substrate, which aregenerally called random materials, and integrating the prepreg pieces,variation occurs in the mechanical properties, and therefore, componentdesign is not feasible. In this regard, since a fiber-reinforced plasticis obtained using a slit-inserted prepreg substrate in the presentinvention, satisfactory mechanical properties are obtained as comparedto the case of using random materials, and variation thereof can also bemade smaller.

The shape of the slits formed in the prepreg substrate is notparticularly limited, and for example, the slit shape may be a straightline shape, a curved line shape, or a broken line shape.

The angle of the slits formed in the prepreg substrate with respect tothe fiber axis of a reinforcing fiber is also not particularly limited.

The length L of the reinforcing fibers that have been cut by slits inthe prepreg substrate are preferably 1 mm to 100 mm, more preferably 3mm to 70 mm, even more preferably 5 mm to 50 mm, particularly preferably10 mm to 50 mm, and most preferably 10 mm to 35 mm. When the length L ofthe reinforcing fibers is more than or equal to the lower limit, afiber-reinforced plastic having sufficient mechanical properties may beeasily obtained. When the length L of the reinforcing fibers is lessthan or equal to the upper limit, since the reinforcing fibers and thematrix resin become easily flowable at the time of molding, it is easyto shape the fiber-reinforced plastic thus obtained into a structuralmaterial having a complicated three-dimensional shape such as a rib.

The fiber volume percentage content (Vf) in the prepreg substrate ispreferably 5% to 70% by volume, more preferably 10% to 60% by volume,and even more preferably 15% to 50% by volume. When the Vf is more thanor equal to the lower limit, a structural material having sufficientmechanical properties may be easily obtained. When the Vf is less thanor equal to the upper limit, satisfactory fluidity may be easilyobtained at the time of shaping.

Meanwhile, the Vf value of a prepreg substrate means the proportion ofthe volume of reinforcing fibers with respect to the total volume ofreinforcing fibers, a matrix resin, and other components such asadditives, excluding voids (gas), in the prepreg substrate. Since the Vfvalue measured according to JIS K7075 is a value that varies dependingon the existing amount of voids in the prepreg substrate, in the presentinvention, a fiber volume percentage content that does not depend on theexisting amount of voids is employed.

The thickness of the prepreg substrate is preferably 50 μm to 500 μm.When the thickness of the prepreg substrate is more than or equal to thelower limit, handling of the prepreg substrate is facilitated.Furthermore, in the case of obtaining material (A) having a desiredthickness by laminating two or more sheets of a prepreg substrate, sincethe number of laminated sheets of the prepreg substrate becoming toolarge can be prevented, productivity is increased. When the thickness ofthe prepreg substrate is less than or equal to the upper limit, voids(pores) inside the prepreg substrate that are generated at the time ofproduction of the prepreg substrate, can be suppressed, and afiber-reinforced plastic having sufficient mechanical properties may beeasily obtained.

According to the present invention, the effect of the thickness of theprepreg substrate on the strength of the structural material that isfinally obtainable is small.

The method for producing a prepreg substrate is not particularlylimited, and any known method can be employed. Regarding the prepregsubstrate, any commercially available prepreg substrate may be used.

Regarding the method for forming slits in the prepreg substrate, forexample, methods of using a laser marker, a cutting plotter, a punchingdie, and the like may be used. A method of using a laser marker ispreferable from the viewpoint that even slits having complicated shapessuch as a curve line shape and a zigzag line shape can be processed athigh speed. A method of using a cutting plotter is preferable from theviewpoint that processing is easily achieved even with a large-sizedprepreg substrate having a length of 2 m or more. A method of using apunching die is preferable from the viewpoint that processing can beachieved at high speed.

In a case in which the material (A) is constituted from a prepreglaminate, in regard to the prepreg laminate, it is preferable to form aresin layer by laminating a resin sheet between the prepreg substratesheets to be laminated. Thereby, fluidity is increased in Step (ii), theisotropy or anisotropy of mechanical properties is controlled, and afiber-reinforced plastic having less variation in the mechanicalproperties can be easily obtained.

The resin that is used in the resin layer described above is notparticularly limited, and for example, the same resin as the matrixresin used in the prepreg substrate may be used. It is preferable thatthe matrix resin used in the resin layer is a resin that is identicalwith the matrix resin used in the prepreg substrate. Meanwhile, it isstill acceptable if the resin used in the resin layer is a resin that isdifferent from the matrix resin used in the prepreg substrate.

(Modes of Lamination)

In a case in which the material (A) is constituted from a prepreglaminate, the mode in which prepreg substrate sheets are laminated inStep (i) is desirably a mode in which the conditions for the angle θ inStep (ii) are satisfied in 66% or more of the prepreg substrate sheetswith respect to the number of laminated sheets of the prepreg substratein the prepreg laminate to be formed. That is, lamination may beperformed by shifting the fiber axial directions of the reinforcingfibers of the prepreg substrate in a particular range such that theconditions for the angle θ in Step (ii) are satisfied in 66% or more ofthe various prepreg substrate sheets with respect to the number oflaminated sheets. In a case in which the prepreg laminate includesprepreg substrate sheets that do not satisfy the above-describedconditions for the angle θ at a proportion of less than 34% relative tothe number of laminated sheets, the fiber axial directions of thereinforcing fibers in the prepreg substrate are not particularlylimited. In regard to the prepreg laminate, it is preferable that theconditions for the angle θ are satisfied in all of the prepreg substratesheets.

Specifically, for example, a mode in which two or more sheets of aprepreg substrate are aligned such that the fiber axes of thereinforcing fibers of the various prepreg substrate sheets are arrangedin the same direction, and then the prepreg substrate sheets arelaminated, may be employed. Since the fiber axial directions of thereinforcing fibers of the various prepreg substrate sheets are alignedin this mode, it is easy to control the angle relations between thetravel direction of the material (A) and the fiber axial directions ofthe reinforcing fibers of the various prepreg substrate sheets such thatthe conditions for the angel θ are satisfied in the various prepregsubstrate sheets in Step (ii).

Furthermore, as long as the conditions for the angle θ in Step (ii) aresubstantially satisfied in each of the prepreg substrate sheets of theprepreg laminate, a mode in which the fiber axial directions of thereinforcing fibers in the various prepreg substrate sheets that havebeen laminated are deviated from one another, is still acceptable. Thatis, when prepreg substrate sheets are laminated, strictly controllingthe angles of the various prepreg substrate sheets so as to completelyalign the fiber axial directions of the reinforcing fibers of thevarious prepreg substrate sheets, is not necessarily essential.

Furthermore, even in a case in which there are deviations in the fiberaxial directions of the reinforcing fibers between the various prepregsubstrate sheets thus laminated, the deviation in the fiber axialdirections of the reinforcing fibers between the various prepregsubstrate sheets that satisfy the conditions for the angle θ of 66% ormore with respect to the number of laminated sheets in the prepreglaminate thus formed, is 40° or less, and preferably 10° or less. As thedeviations in the fiber axial directions of the reinforcing fibersbetween the various prepreg substrate sheets that satisfy the conditionsfor the angle θ are smaller, it becomes easier to control the anglerelations between the travel direction of the material (A) and the fiberaxial directions of the reinforcing fibers of the various prepregsubstrate sheets so as to satisfy the conditions for the angle θ in thevarious prepreg substrate sheets in Step (ii).

The number of laminations of the prepreg substrate in the prepreglaminate is preferably 2 to 16, and more preferably 4 to 12. When thenumber of laminations of the prepreg substrate is more than or equal tothe lower limit, a fiber-reinforced plastic having sufficient mechanicalproperties may be easily obtained. When the number of laminations of theprepreg substrate is less than or equal to the upper limit, thelaminating operation is facilitated, and excellent productivity isobtained.

The thickness of the material (A) is preferably 0.25 mm to 6.0 mm, morepreferably 0.4 mm to 6.0 mm, and even more preferably 0.6 mm to 4.0 mm.When the thickness of the material is more than or equal to the lowerlimit, a fiber-reinforced plastic having sufficient mechanicalproperties may be easily obtained. When the thickness of the material(A) is less than or equal to the upper limit, the fiber axial directionsof the reinforcing fibers in the material (A) are more easily randomizeddue to the pressing in Step (ii) as will be described below, and afiber-reinforced plastic which exhibits easily controllable isotropy oranisotropy in the mechanical properties and has less variation in themechanical properties, may be easily obtained.

[Step (ii)]

In Step (ii), the material (A) is pressed using a pressing apparatusthat can press the material (A) in the thickness direction such thatpressing is achieved approximately uniformly in a direction orthogonalto the travel direction of the material (A), while the material (A) iscaused to travel in one direction, in a state in which the material (A)is heated to a temperature T that is higher than or equal to the meltingpoint of the matrix resin, or is higher than or equal to the glasstransition temperature if the matrix resin does not have a meltingpoint.

In Step (ii), the angles θ formed by the fiber axial directions of thereinforcing fibers of the prepreg substrate in the material (A) withrespect to a direction orthogonal to the travel direction of thematerial (A), are adjusted to −20° to 20° at the time of pressing by thepressing apparatus. When a prepreg laminate is used as the material (A),even in a case in which the fiber axial directions of the reinforcingfibers between various prepreg substrate sheets are shifted from oneanother, the conditions for the angle θ described above should besatisfied in 66% or more of the prepreg substrate sheets with respect tothe number of laminated sheets.

When the material (A) is pressed with a pressing apparatus as describedabove in a state in which the matrix resin is melted by heating thematerial (A) to the temperature T, the reinforcing fibers that have beencut by the slits flow together with the matrix resin, and the fiberaxial directions of the reinforcing fibers change to various directions.Thereby, the fiber axial directions of the reinforcing fibers that havebeen aligned in an identical direction in the material (A) arerandomized, and a fiber-reinforced plastic which exhibits easilycontrollable isotropy or anisotropy in the mechanical properties and hasless variation in the mechanical properties, can be obtained.

The angles θ are preferably −5° to 5°. When the angles θ are in therange described above, the fiber axial directions of the reinforcingfibers in the material (A) may be randomized more easily by pressingwith press rolls, and a fiber-reinforced plastic which exhibitscontrollable isotropy or anisotropy in the mechanical properties and hasless variation in the mechanical properties, may be easily obtained.

Temperature T is a temperature higher than or equal to the melting pointof the matrix resin impregnated in the prepreg substrate, or atemperature higher than or equal to the glass transition temperature ofthe matrix resin if the matrix resin does not have a melting point. In acase in which the material (A) includes two or more kinds of matrixresins, the temperature T is to be based on the highest temperatureamong the melting points or glass transition temperatures of thosematrix resins.

The temperature T may vary depending on the kind of the matrix resin;however, in the range in which the matrix resin melts, the temperature Tis preferably 150° C. to 450° C., and more preferably 200° C. to 400° C.When the temperature T is in the range described above, the reinforcingfibers and the matrix resin may be easily flowed, and a fiber-reinforcedplastic which exhibits controllable isotropy or anisotropy in themechanical properties and has less variation in the mechanicalproperties, may be easily obtained.

In Step (ii), the material (A) may be preheated before the material (A)is heated to the temperature T. In the case of performing preheating,the preheating temperature is preferably 150° C. to 400° C., and morepreferably 200° C. to 380° C. In the stage of preheating, the matrixresin of the material (A) may be in a molten state, or may not be in amolten state.

The method for preheating the material (A) is not particularly limited,and examples include methods of using an IR heater, a hot aircirculating oven, and the like.

The linear pressure employed at the time of pressing the material (A) ispreferably 3 N/m to 100 N/m, and more preferably 5 N/m to 50 N/m. Whenthe linear pressure is in the range described above, a fiber-reinforcedplastic which exhibits controllable isotropy or anisotropy in themechanical properties and has less variation in the mechanicalproperties, may be easily obtained.

The time for pressing the material (A) is preferably 0.1 minutes to 30minutes, and more preferably 0.5 minutes to 10 minutes. The pressingtime can be regulated by the travel speed of the material (A), and inthe case of using a pressing apparatus having press rolls as will bedescribed below, the pressing time can be regulated by the number ofpairs of the press rolls used.

The travel speed of the material (A) in Step (ii) is preferably 0.1m/min to 25 m/min, more preferably 0.2 m/min to 20 m/min, and even morepreferably 0.5 m/min to 15 m/min. When the travel speed of the material(A) is more than or equal to the lower limit, productivity is increased.When the travel speed of the material (A) is less than or equal to theupper limit, a fiber-reinforced plastic which exhibits controllableisotropy or anisotropy in the mechanical properties and has lessvariation in the mechanical properties, may be easily obtained.

When the linear pressure, the pressing time, and temperature T arecontrolled at the time of pressing the material (A) in Step (ii), themechanical properties of the fiber-reinforced plastic thus obtainablecan have excellent isotropy, and also, anisotropy of the mechanicalproperties can be controlled as desired.

Regarding Step (ii), Step (ii-1) in which material (A) is pressed in astate of being heated to temperature T while being caused to travel inone direction, by means of a pressing apparatus equipped with at least apair of press rolls whose shaft line direction is a direction orthogonalto the travel direction of the material (A), is preferred.

In Step (ii-1), as illustrated in FIG. 1, the shaft line direction of apair of press rolls 10 is coincident with a direction orthogonal to thetravel direction of the material (A). Material (A) 100 is pressed in astate of being heated to temperature T while being caused to travel inone direction, using the pair of press rolls 10. At this time, pressingof the material (A) is performed such that the angles θ formed by thedirections Y of the fiber axes of reinforcing fibers 110 of the prepregsubstrate in the material (A) 100 with respect to direction X that isorthogonal to the travel direction of the material (A), are in the rangeof −20° to 20°.

In regard to the pair of press rolls, the shaft line directions of upperpress rolls and lower press rolls are coincident.

Regarding the method of heating the material (A) to temperature T inStep (ii-1), a method of pressing the material (A) while heating usingheated rolls as the press rolls.

When a state in which the material (A) is heated to the temperature Twhen pressed with press rolls can be secured by simply heating thematerial (A) before pressing, press rolls that do not have a heatingfunction may be used. Furthermore, in a case in which the material (A)can be heated to the temperature T only by using heated rolls that areused as press rolls, preheating may not be performed.

In Step (ii-1), only a pair of press rolls in a single row may be used,or two or more pairs of press rolls in two or more rows may also beused. In a case in which vertically pairing press rolls are provided intwo or more rows in Step (ii-1), the angles θ are adjusted to −20° to20° for all of the press rolls.

In Step (ii-1), it is preferable to use a double belt-type heat pressmachine that interposes material (A) with at least a pair of belts,heats the material (A) while causing the material (A) to travel so as topass through between at least a pair of press rolls, and presses thematerial (A) with at least the pair of press rolls. In this case, it ispreferable to dispose release paper or release film between the material(A) and the belts, or to have the belt surfaces subjected in advance toa release treatment. The material for the belt is not particularlylimited, and from the viewpoints of heat resistance and durability,belts made of metals are preferred.

Meanwhile, Step (ii-1) is not intended to be limited to the mode ofcarrying out the process using a double belt-type heat press machine.For example, a mode in which a band-shaped material (A) is pressed witha pair of press rolls while the material (A) is caused to travel withoutbeing interposed between a pair of belts, may also be employed.

Step (ii) is not limited to the mode of using a pressing apparatusequipped with at least a pair of press rolls. For example, a mode ofperforming pressing using a pressing apparatus that presses with a flatsurface and a press roll; a pressing apparatus based on pressing platesthat presses with a flat surface and a flat surface; or a pressingapparatus equipped with plural spherical presses, may also be used.

[Step (iii)]

In Step (iii), a fiber-reinforced plastic is obtained by cooling thematerial (A) that has been pressed with a pressing apparatus in Step(ii). In a case in which the matrix resin is a thermoplastic resin, afiber-reinforced plastic is obtained by lowering the temperature of thematerial (A) to a temperature below the melting point or the glasstransition temperature of the thermoplastic resin and therebysolidifying the material (A).

In the case of using a prepreg laminate as the material (A), thefiber-reinforced plastic thus obtainable is in the form of a sheet inwhich various prepreg substrate sheets are adhered and integrated.Therefore, even in the case of using a prepreg laminate, thefiber-reinforced plastic thus obtainable can be easily handled.

The method for cooling the material (A) is not particularly limited, andfor example, a method of using warm water rolls may be used. A method ofcooling by naturally cooling the material (A) may also be employed.

The cooling time is preferably 0.5 minutes to 30 minutes.

EXAMPLE OF EMBODIMENTS

In the following description, an example of using a double belt-typeheat press machine 1 illustrated in FIG. 2 (hereinafter, simply referredto as heat press machine 1) will be explained as an example of anembodiment of carrying out Step (ii-1) and Step (iii). Meanwhile, theembodiment of carrying out Step (ii) and Step (iii) is not limited tothe embodiment of using the heat press machine 1.

The heat press machine 1 has a pair of belts 12 that cause a band-shapedmaterial (A) 100 to travel in one direction in a state of having thematerial (A) vertically interposed therebetween; a pair of IR heaters 14that preheat the material (A); three pairs of press rolls 10 in threerows, which vertically interpose the preheated material (A) 100 andpress the material (A) 100; three pairs of warm water rolls 16 in threerows, which vertically interpose the pressed material (A) 100 and coolthe material (A) 100; and a winding roll 18 that winds afiber-reinforced plastic 120 that has been cooled and solidified, thushaving various prepreg substrate sheets integrated together.

A pair of press rolls 10 press the material (A) 100 while movingrotationally in the direction in which the material (A) 100 that passesthrough between the press rolls is sent to the downstream side. A pairof warm water rolls cool the material (A) 100 while moving rotationallyin the direction in which the material (A) 100 that passes through thewarm water rolls is sent to the downstream side.

A pair of belts 12 are each mounted to rotate by means of a driving roll20 provided on the upstream side of the IR heaters 14, and a driven roll22 provided on the downstream side of the warm water rolls 16, and eachbelt is moved rotationally by the driving roll 20. The material (A) 100is caused to travel as the pair of belts 12 move rotationally in a stateof having the material (A) 100 interposed therebetween.

In the mode of using this heat press machine 1, as Step (ii-1), aband-shaped material (A) 100 is continuously supplied to the heat pressmachine 1 such that the angles formed by the fiber axial directions ofthe reinforcing fibers in the material (A) 100 with respect to the shaftline direction of the rolls are in the range of −20° to 20°.Specifically, a band-shaped material (A) 100 in which the fiber axialdirections of the reinforcing fibers are at −20° to 20° with respect toa direction orthogonal to the travel direction, is continuously suppliedin the length direction to the heat press machine 1. In the heat pressmachine 1, since the shaft line direction of the pair of press rolls 10is coincident with the direction orthogonal to the travel direction ofthe material (A) 100 thus supplied, the angles are in the range of −20°to 20°.

Inside the heat press machine 1, the material (A) 100 is preheated bythe IR heaters 14 while being caused to travel so as to pass throughbetween the pair of press rolls 10 in a state of being interposedbetween the pair of belts 12, and the material (A) 100 is pressed in astate of being heated to temperature T by the press rolls 10. Thereby,the matrix resin and the reinforcing fibers in the material (A) 100 arefluidized, and the fiber axial directions of the reinforcing fibers arerandomized.

In this example, it is preferable to perform pressing of the material(A) 100 simultaneously with heating to temperature T, using heated rollsas the press rolls 10. Meanwhile, in a case in which the material (A)100 can be pressed by the press rolls 10 in a state of being heated totemperature T only by preheating with the IR heaters 14, the material(A) 100 may be simply pressed without being heated upon passing throughbetween the press rolls 10.

Next, as Step (iii), the material (A) 100 that has been pressed by thepress rolls 10 is caused to travel so as to pass through between thepair of warm water rolls 16 in a state of being interposed between thepair of belts 12, and is cooled by the warm water rolls 16. Thereby, aband-shaped fiber-reinforced plastic 120 is obtained.

The fiber-reinforced plastic 120 thus obtained is detached from the pairof belts 12 on the downstream side of the driven rolls 22, and then iswound around a winding roll 18 via a guide roll 24.

A double belt-type heat press machine such as the heat press machine 1is advantageous from the viewpoint that a series of processes includingheating, pressing, and cooling of the material (A) can be carried outconveniently.

[Operating Effect]

In the production method of the present invention described above, whenthe angles θ are controlled to a particular range, and the material (A)is pressed using a particular pressing apparatus in Step (ii), thereinforcing fibers are fluidized, and the fiber axial directions arerandomized. Thereby, a fiber-reinforced plastic which has excellentmechanical properties such as strength, has the isotropy or anisotropyof the mechanical properties well-controlled, has less variation, andalso has excellent heat resistance, can be obtained. Therefore, when afiber-reinforced plastic obtained by the production method of thepresent invention is shaped, a structural material which has excellentmechanical properties, has the isotropy or anisotropy of the mechanicalproperties well-controlled, has less variation, and has excellent heatresistance, can be produced.

As such, according to the method of the present invention, afiber-reinforced plastic which has excellent mechanical properties, hasthe isotropy or anisotropy of the mechanical properties well-controlled,has less variation, and also has excellent heat resistance, can beproduced using a material (A) in which the fiber axial directions of thereinforcing fibers of the prepreg substrate are biased in a particularrange. Therefore, in a case in which a band-shaped fiber-reinforcedplastic is continuously produced, it is not necessary to respectivelyproduce prepreg substrates having different fiber axial directions ofthe reinforcing fibers, and production is convenient and advantageous inview of cost. Also, in the case of producing sheets of afiber-reinforced plastic, laminating the fiber-reinforced plastic sheetswhile various prepreg substrate sheets are frequently rotated atpredetermined angles of rotation so that the fiber axial directions ofthe reinforcing fibers are not biased, is not necessary. Therefore, evenin the case of using a prepreg laminate, the lamination operation isconvenient and easily controllable, and it is also advantageous in viewof cost.

Furthermore, in the fiber-reinforced plastic obtainable by theproduction method of the present invention, since the reinforcing fibersare cut by the slits formed in the prepreg substrate, thefiber-reinforced plastic has high fluidity at the time of shaping, andcan be suitably used for the production of a structural material havinga complicated shape such as a three-dimensional shape.

The production method of the present invention is not limited to themethod of using the heat press machine 1 as described above. Forexample, a method for producing sheets of fiber-reinforced plastic bysupplying sheets of the material (A) to a double belt-type heat pressmachine may also be used.

Furthermore, a method in which preheating of the material (A) is notperformed in Step (ii-1) may also be used. Also, a method of using adouble belt-type heat press machine equipped with two or more pairs ofbelts may also be used. In a case in which a band-shapedfiber-reinforced plastic is produced continuously, or the like, a methodof performing Step (ii-1) and Step (iii) while causing the band-shapedmaterial (A) to travel as received without being interposed betweenbelts, may also be used. Furthermore, a method of separately using anapparatus exclusive for preheating, an apparatus exclusive for pressing,and an apparatus exclusive for cooling, may also be used.

<Fiber-Reinforced Plastic>

A fiber-reinforced plastic that uses carbon fibers as reinforcing fibers(hereinafter, also referred to as carbon fiber-reinforced plastic),which is obtainable by the production method of the present invention,is preferable from the viewpoint of having more satisfactory mechanicalcharacteristics, having much less variation, having more satisfactoryheat resistance, and also having more satisfactory fluidity at the timeof shaping.

The carbon fiber-reinforced plastic of the present invention is afiber-reinforced plastic including carbon fibers and a matrix resin, inwhich the fiber length of the carbon fibers is 1 mm to 100 mm, thedegree of orientation pf of the carbon fibers in a direction thatorthogonally intersects the thickness direction is 0.001 to 0.8, and theeccentricity coefficient ec of the orientation profile of the carbonfibers in a plane that orthogonally intersects the thickness directionis 1×10⁻⁵ to 9×10⁻⁵. The carbon fiber-reinforced plastic of the presentinvention is obtained by using the method for producing afiber-reinforced plastic of the present invention described above, andusing carbon fibers as the reinforcing fibers.

[Fiber Length]

The length of the carbon fibers is 1 mm to 100 mm, preferably 3 mm to 70mm, more preferably 5 mm to 50 mm, even more preferably 10 mm to 50 mm,and particularly preferably 10 mm to 35 mm. When the fiber length of thecarbon fibers is more than or equal to the lower limit, requiredmechanical characteristics may be easily obtained. When the fiber lengthof the carbon fibers is less than or equal to the upper limit, fluidityneeded at the time of shaping may be easily obtained.

[Method for Measuring Fiber Length]

The resin in a carbon fiber-reinforced plastic is burned off to take outcarbon fibers only, and the fiber lengths of the carbon fibers aremeasured with a vernier caliper or the like. Measurement is made forrandomly selected one hundred carbon fibers, and the fiber length iscalculated as the mass average of the values.

[Degree of Orientation Pf]

The state of orientation of carbon fibers in a direction orthogonallyintersecting the thickness direction in the carbon fiber-reinforcedplastic of the present invention is represented by the degree oforientation pf. When it is said that the pf is “zero (0)”, it means thatthe carbon fibers are oriented in an idea state in a directionorthogonally intersecting the thickness direction of the carbonfiber-reinforced plastic. A larger value of pf indicates that the degreeof disarrangement of the carbon fibers toward the outside of a planethat orthogonally intersects the thickness direction is higher.

The pf of the carbon fiber-reinforced plastic of the present inventionis 0.001 to 0.8. Although fluidity at the time of shaping may varydepending on the fiber length of the carbon fibers, as the value of phis larger, it is more difficult to obtain fluidity at the time ofshaping due to entanglement of the carbon fibers or friction between thecarbon fibers. That is, as the carbon fibers are disarranged toward theoutside of a plane that orthogonally intersects the thickness direction,entanglement of the carbon fibers or friction between the carbon fibersis prone to occur, and it is difficult to obtain fluidity at the time ofshaping. In a case in which the fiber length of the carbon fibers is 1mm to 100 mm, when the pf is 0.8 or less, sufficient fluidity isobtained at the time of shaping, and sufficient mechanical propertiesare also obtained. The lower limit of the pf is not particularlyrestricted in view of the physical properties of the carbonfiber-reinforced plastic. However, it is difficult to adjust the pf tozero (0), and 0.001 or greater is a realistic value. The upper limit ofthe pf is preferably 0.5, more preferably 0.3, and even more preferably0.15.

[Method for Measuring Pf]

As illustrated in FIG. 3, a measurement sample 210 having a width of 2mm is cut out from a carbon fiber-reinforced plastic 200 having athickness of 2 mm, and measurement is performed as follows.

The width direction in the measurement sample 210 is designated asx-direction, the thickness direction as y-direction, and the lengthdirection as z-direction.

(Actually Measured Integral Value in x-Direction)

A measurement sample 210 is irradiated with X-radiation in thex-direction, and a one-dimensional orientation profile originating fromdiffraction of the 002 plane of graphite is obtained. Theone-dimensional orientation profile originating from diffraction of the002 plane of graphite is obtained by a method of inputting an imageusing a two-dimensional detector, and then obtaining a profile in thecircumferential direction with regard to the 002 diffraction part usingan analytic software program. Furthermore, with a one-dimensionaldetector, a one-dimensional orientation profile originating fromdiffraction of the 002 plane of graphite may also be obtained by fixingthe detector at the site of the 002 diffraction and rotating the sample360°.

Next, the actually measured integral value Sx in the x-direction iscalculated by the following Expression (1) from the one-dimensionalorientation profile thus obtained.

[Mathematical Formula 1]

Sx=∫ ₀ ^(2π) I(δ)dδ  (1)

Here, in Expression (1), 1(δ) is the intensity obtainable at the azimuthangle δ based on the z-direction in a yz plane in the one-dimensionalorientation profile.

When the carbon fibers are perfectly oriented in the x-direction, the Sxhas the maximum value. As the carbon fibers have a gradient in thex-direction, the value of Sx becomes smaller. Factors that make Sxsmaller include the component in the thickness direction in the gradientwith respect to the x-direction of the carbon fibers, and the componentin a plane that orthogonally intersects the thickness direction. Thatis, both the component in the yz plane and the component in the xz planewith respect to the x-direction of the carbon fibers are the factorscausative of the decrease in Sx. In regard to the pf, since the degreeof disarrangement of carbon fibers toward the outside of a plane thatorthogonally intersects the thickness direction is evaluated, thefollowing operation is performed in order to eliminate the effect of thecomponent within the xz plane on the gradient of the carbon fibers.

(Predicted Integral Value in x-Direction)

A measurement sample 210 is irradiated with X-radiation in they-direction, and a one-dimensional orientation profile originating fromdiffraction of the 002 plane of graphite is obtained. Subsequently, I(φ)is normalized by the following Expression (2), and the fiber proportionG(φ) at the azimuth angle φ is calculated.

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Formula}\mspace{14mu} 2} \right\rbrack & \; \\{{G(\phi)} = \frac{I(\phi)}{\int_{0}^{2\pi}{{I(\phi)}\ d\; \phi}}} & (2)\end{matrix}$

Here, in Expression (2), I(φ) is the intensity obtainable at the azimuthangle q based on the z-direction in the xz plane in the one-dimensionalorientation profile.

Next, the predicted integral value F in the x-direction is calculated bythe following Expression (3).

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Formula}\mspace{14mu} 3} \right\rbrack & \; \\{F = {2\frac{Va}{Vb}{\int_{0}^{\pi}{{G(\phi)}{A(\phi)}\ d\; \phi}}}} & (3)\end{matrix}$

Here, Va represents the fiber volume percentage content (Vf) of carbonfibers in the measurement sample 210; Vb represents the fiber volumepercentage content (Vf) of carbon fibers in a standard sample forcorrection that will be described below. A(φ) represents the coefficientfor intensity correction.

The coefficient for intensity correction A(φ) is determined as follows.

As a standard sample for correction, a UD material having a thickness of2 mm is produced, in which carbon fibers are unidirectionally arrangedin parallel such that the carbon fibers are perfectly oriented in thez-direction, and this is designated as a 0° material. Regarding thecarbon fibers and the matrix resin used in the standard sample, the samekinds of carbon fibers and matrix resin as the measurement sample 210are used. Va, the fiber volume percentage content (Vf) of carbon fibersin the measurement sample 210, and Vb, the fiber percentage content (Vf)of carbon fibers in the standard sample, may be identical or may bedifferent.

Subsequently, as a new standard sample, a 15° material is produced inthe same manner as in the 0° material, except that carbon fibers areunidirectionally arranged in parallel such that the azimuth angle ψ isperfectly oriented in the direction of 15°. Similarly, a 30° material, a45° material, a 60° material, a 75° material, and a 90° material areproduced, in which carbon fibers are unidirectionally arranged inparallel such that the azimuth angle φ is perfectly oriented in thedirections of 30°, 45°, 60°, 75°, and 90°, respectively.

Next, standard measurement samples each having a width of 2 mm are cutout from the various standard samples in the same manner as in the caseof the measurement sample 210. For each standard measurement sample,X-radiation is caused to enter the sample in the x-direction, and aone-dimensional orientation profile originating from diffraction of the002 plane of graphite is obtained. In the one-dimensional orientationprofile of the standard measurement sample originating from the 90°material, the intensity has an almost constant value. From theone-dimensional orientation of each of the various standard measurementsamples, the integral value S(φ) of the intensity I(φ,δ) of the materialof the azimuth angle cp is calculated by the following Expression (4).

[Mathematical Formula 4]

S(φ)=∫₀ ^(2π) I(φ,δ)dδ  (4)

Here, I(φ,δ) represents the intensity obtainable at the azimuth angle δfor the standard measurement sample of the azimuth angle φ.

The integral value S(φ) is in the relation: S(φ)=S(π−φ). A graph isproduced by plotting φ on the horizontal axis and plotting S(φ) on thevertical axis, and a resultant obtained by performing normaldistribution approximation at φ in the range of 0° to 180° is designatedas the intensity correction coefficient A(φ) at the azimuth angle φ.

(Corrected Predicted Integral Intensity in x-Direction)

The predicted integral value F in the x-direction and the actuallymeasured integral value Sx do not necessarily coincide. Thus, theintegral value correction coefficient B(Sx) is calculated using standardsamples.

Standard measurement samples are cut out from various standard samplesin the same manner as in the case of the calculation of the intensitycorrection coefficient A(φ). For each of the various standardmeasurement samples, the actually measured integral value Sx(α) iscalculated by the method for calculating the actually measured integralvalue in the x-direction as described above. Meanwhile, α is 0°, 15°,30°, 45°, 60°, 75°, or 90°. Furthermore, for each of the variousstandard measurement samples, the predicted integral value F(α) in thex-direction is determined by the method for calculating the predictedintegral value in the x-direction as described above. When a graph isproduced by plotting Sx(α) on the horizontal axis and plottingSx(α)/F(α) on the vertical axis, a high correlation is found. Aresultant of performing linear approximation is designated as theintegral correction coefficient B(Sx).

The predicted integral value F in the x-direction is multiplied by theintegral correction coefficient B(Sx), and the product is designated asthe corrected predicted integral intensity F′ in the x-direction.

(Calculation of Pf)

The pf is calculated by the following Expression (5).

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Formula}\mspace{14mu} 5} \right\rbrack & \; \\{{Pf} = {{\frac{F^{\prime}}{Sx} - 1}}} & (5)\end{matrix}$

[Eccentricity Coefficient Ec]

Dispersibility of the two-dimensional orientation of carbon fibers in aplane that orthogonally intersecting the thickness direction in thecarbon fiber-reinforced plastic according to the present invention, canbe represented by the eccentricity coefficient ec of the orientationprofile of carbon fibers in the relevant plane. ec is the eccentricitycoefficient from an approximate ellipse of the orientation profile.

The ec of the carbon fiber-reinforced plastic of the present inventionis 1×10⁻⁵ to 9×10⁻⁵. In a carbon fiber-reinforced plastic in which thereinforcing fibers are randomly oriented, a larger value of ec meanslarger variation in the mechanical properties.

When the ec is 9×10⁻⁵ or less, variation in the mechanical propertiescan be suppressed. The ec of the carbon fiber-reinforced plastic of thepresent invention is preferably 8.5×10⁻⁵ or less, and more preferably8×10⁻⁵ or less.

There are no particular limitations on the preferred lower limit of ec,in view of the mechanical properties of the carbon fiber-reinforcedplastic. However, for example, as the fiber length of the carbon fibersbecomes longer, the difficulty in the production of a carbonfiber-reinforced plastic having a small value of ec increases. When thefiber length of the carbon fibers is lengthened, mechanicalcharacteristics are enhanced; however, the value of ec tends to increasealong with the enhancement. Thus, variation in the mechanical propertiesincreases. When the balance between the mechanical characteristics andthe variation thereof is considered, a preferred lower limit, which isrealistic from the viewpoint of production, of ec according to the fiberlength of the carbon fiber is as follows. In a case in which the fiberlength of the carbon fibers is 1 mm to 3 mm, the ec is preferably 1×10⁻⁵or more. In a case in which the fiber length of the carbon fibers ismore than 3 mm and 10 mm or less, the ec is preferably 1.5×10⁻⁵ or more.In a case in which the fiber length of the carbon fibers is more than 10mm and 35 mm or less, the ec is preferably 2×10⁻⁵ or more. In a case inwhich the fiber length of the carbon fibers is more than 35 mm and 70 mmor less, the ec is preferably 3×10⁻⁵ or more. In a case in which thefiber length of the carbon fibers is more than 70 mm and 100 mm or less,the ec is preferably 4×10⁻⁵ or more.

[Method for Measuring Ec]

The profile of intensity I(φ) at the azimuth angle φ, which is measuredwhen the predicted integral value in the x-direction is determined uponmeasurement of the pf, is approximated as an ellipse Ia(φ) representedby the following Expression (6).

[Mathematical Formula 6]

Ia(φ)={a ² cos²(φ−β)+b ² sin²(φ−β)}^(1/2)  (6)

Here, in Expression (6), a represents the major axis of the ellipse; brepresents the minor axis of the ellipse; and β represents the angle ofrotation.

The numerical values of a, b, and β in a case in which Ia(φ) approachesmost closely to I(φ) may be calculated such that the eccentricity R froman ellipse, which is represented by the following Expression (7), hasthe minimum value. Further, the minimum value of the eccentricity R inthat case is designated as ec.

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Formula}\mspace{14mu} 7} \right\rbrack & \; \\{R = {\frac{1}{{Number}\mspace{14mu} {of}\mspace{14mu} {measurement}\mspace{14mu} {sites}}{\sum\left( {{I(\phi)} - {{Ia}(\phi)}} \right)^{2}}}} & (7)\end{matrix}$

[Dispersion Parameter Dp]

Three-dimensional dispersion of carbon fibers in the carbonfiber-reinforced plastic of the present invention is represented by thedispersion parameter dp of carbon fibers in a cross-section in thethickness direction of the carbon fiber-reinforced plastic. When it issaid that dp is “100”, it means that carbon fibers are dispersed in amatrix resin in an ideal state. As the value of dp is smaller, it isimplied that the proportion of carbon fibers locally aggregated is high,and the proportion of resin-rich parts is high.

The dp of the carbon fiber-reinforced plastic of the present inventionis preferably 80 to 100.

As the value of dp is smaller, and the dispersibility of carbon fibersis poorer, heat resistance becomes inferior. When dp is 80 or more,satisfactory heat resistance may be easily obtained. The dp of thecarbon fiber-reinforced plastic of the present invention is preferably84 or more, and more preferably 88 or more. The upper limit of dp of thecarbon fiber-reinforced plastic of the present invention istheoretically 100. A preferred upper limit of dp that is realistic fromthe viewpoint of production is 98.

Fluidity at the time of shaping of the carbon fiber-reinforced plasticis generated by the flow of resin or slipping of a resin layer at thetime of shaping. Therefore, as the path through which the resin in thecarbon fiber-reinforced plastic can flow is wider, higher fluidity isobtained at the time of shaping. That is, as the value of dp is smaller,fluidity at the time of shaping is higher. However, in regard to thecarbon fiber-reinforced plastic of the present invention, since the pfis controlled to the range described above, even if the value of dp ishigh, high fluidity is exhibited.

[Method for Measuring Dp]

dp can be measured by processing a photograph of a cross-section in thethickness direction of a sample specimen cut out from a carbonfiber-reinforced plastic, using an image editing software program.

Specifically, for example, a sample specimen is cut out from a carbonfiber-reinforced plastic, and a cross-sectional photograph of the samplespecimen is taken. For the process of taking the cross-sectionalphotograph, for example, an optical microscope can be used. From theviewpoint that the accuracy of evaluation based on dp becomes higher,the dot pitch for the resolution at the time of photograph taking ispreferably 1/10 or less, and more preferably 1/20 or less, of thediameter of the carbon fibers.

Next, the photograph of cutting is processed as follows using an imageediting software program.

In the photograph of cutting, a portion corresponding to the extent of arectangle having a size of 2 mm in the thickness direction in across-section of the sample specimen and 1.5 mm in a directionorthogonal to the thickness direction, is assigned as a processingobject image. The processing object image is subjected to binarizationinto carbon fiber parts, and resin parts as well as void parts using theimage editing software program. For example, a processing object imagein which carbon fiber parts are indicated in white, resin parts areindicated in grey, and void parts are indicated in black, is subjectedto binarization by presenting the carbon fiber parts in black, and theresin parts as well as the void parts in green.

In a cut surface of a carbon fiber-reinforced plastic having a radius ofcarbon fibers of r (μm) and a fiber volume percentage content of Vf (vol%), the length of one edge, La, of a unit regular hexagon H obtainablewhen carbon fibers C have been theoretically perfectly dispersed asillustrated in FIG. 4, can be determined by the following Expression(8).

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Formula}\mspace{14mu} 8} \right\rbrack & \; \\{{La} = \frac{\sqrt{\frac{2\; \pi}{Vf}} \times r}{\sqrt[4]{27}}} & (8)\end{matrix}$

In regard to the carbon fiber parts of the processing object image afterbinarization, it is assumed that the carbon fibers are theoreticallyperfectly dispersed as illustrated in FIG. 4. Then, the radius of thecarbon fiber is lengthened by the portion of the length Le representedby the following Expression (9), and the carbon fiber parts that havebeen binarized by the image editing software program are expanded suchthat the radius of the carbon fiber becomes La. Meanwhile, Le is adistance corresponding to a half of the distance at a site where thedistance between outer wall surfaces of adjoining carbon fibers is thelargest, in a state in which carbon fibers are ideally dispersed. If theexpansion treatment is carried out when carbon fibers are indeed ideallydispersed in the carbon fiber parts that have been binarized, the carbonfiber parts occupy the entire area of the processing object image.

After the expansion treatment using the image editing software describedabove, dp is calculated by the following Expression (10).

$\begin{matrix}\left\lbrack {{Mathematical}\mspace{14mu} {Expression}\mspace{14mu} 9} \right\rbrack & \; \\{{Le} = {{{La} - r} = {r \times \left( {\frac{\sqrt{\frac{2\pi}{Vf}}}{\sqrt[4]{27}} - 1} \right)}}} & (9) \\{{dp} = {\left( {S\; {1/S}\; 2} \right) \times 100}} & (10)\end{matrix}$

Here, in Expression (10), S1 represents the area of carbon fiber partsafter the expansion treatment in the processing object image; and S2represents the total area of the processing object image.

The carbon fibers or matrix resin that constitute the carbonfiber-reinforced plastic of the present invention are as explained inconnection with the method for producing a fiber-reinforced plasticdescribed above.

The fiber volume percentage content (Vf) of carbon fibers in the carbonfiber-reinforced plastic is preferably 5% to 70% by volume, morepreferably 10% to 60% by volume, and even more preferably 15% to 50% byvolume. When the Vf of the carbon fibers is less than or equal to theupper limit, a decrease in the interfacial strength caused by decreasedtoughness does not easily occur, and fluidity at the time of shaping isalso not easily decreased. When the Vf of the carbon fibers is more thanor equal to the lower limit, the mechanical characteristics needed for afiber-reinforced plastic may be easily obtained.

Meanwhile, the Vf value of a fiber-reinforced plastic means theproportion of reinforcing fibers relative to the total volume of thereinforcing fibers, matrix resin, and other components such asadditives, excluding voids (gas), in the fiber-reinforced plastic. Sincethe Vf value measured according to JIS K7075 is a value that variesdepending on the existing amount of voids in the fiber-reinforcedplastic, in the present invention, a fiber volume percentage contentthat does not depend on the existing amount of voids is employed.

The carbon fiber-reinforced plastic of the present invention may includeother reinforcing fibers in addition to carbon fibers, and additives, tothe extent that the purposes of the present invention are not impaired.

Examples of the other reinforcing fibers include glass fibers, organicfibers, and metal fibers.

Examples of the additives include a non-fibrous filler, a flameretardant, a pigment, a mold releasing agent, a plasticizer, and asurfactant.

The thickness of the carbon fiber-reinforced plastic of the presentinvention is preferably 0.1 mm to 10.0 mm, and more preferably 0.25 mmto 6.0 mm. When the thickness is less than or equal to the upper limit,the matrix resin does not easily squeeze out at the time of pressing inStep (ii), and the thickness can be easily controlled. When thethickness is more than or equal to the lower limit, the carbonfiber-reinforced plastic is easily subjected to shear stress at the timeof pressing in Step (ii), and carbon fibers are randomized so that itbecomes easy to control isotropy or anisotropy of the mechanicalcharacteristics.

Hereinafter, the present invention will be explained in detail by way ofExamples, but the present invention is not intended to be limited by thefollowing description.

[Evaluation of Mechanical Properties]

A bending test specimen having a length of 100 mm and a width of 25 mmwas cut out from a fiber-reinforced plastic thus obtained, using a wettype cutter, and a three-point bending test was performed according tothe test method defined in JIS K7074. At this time, a bending testspecimen in which the longitudinal direction of the specimen wascoincident with the MD direction (direction 90° to the shaft linedirection of rolls) at the time of producing the fiber-reinforcedplastic, and a bending test specimen in which the longitudinal directionof the specimen was coincident with the TD direction (shaft linedirection of rolls) were respectively produced, and then the test wasperformed. Regarding the testing machine, an Instron universal testerModel 4465 was used. Furthermore, the test was performed at roomtemperature (23° C.) and at 80° C. The number of test specimens used formeasurement was respectively set to n=6, the average value of thosespecimens was calculated, and the average value was designated asflexural strength. A standard deviation was calculated from the measuredvalues of flexural strength, and the standard deviation was divided bythe average value to calculate the coefficient of variation (CV value,unit: %), which is an index of variation.

The flexural strength ratio σ_(A)/σ_(B) was calculated. Here, σ_(A)represents the flexural strength measured at room temperature for abending test specimen, in which the longitudinal direction coincidedwith the MD direction at the time of producing the fiber-reinforcedplastic. σ_(B) represents the flexural strength measured at roomtemperature for a bending test specimen, in which the longitudinaldirection coincided with the TD direction at the time of producing thefiber-reinforced plastic.

The flexural strength ratio σ_(C)/σ_(D) was calculated. Here, σ_(C)represents the average value of the flexural strengths measured at 80°C. for a bending test specimen in which the longitudinal directioncoincided with the MD direction at the time of producing thefiber-reinforced plastic, and a bending test specimen in which thelongitudinal direction coincided with the TD direction. σ_(D) representsthe average value of the flexural strengths measured at room temperaturefor a bending test specimen in which the longitudinal directioncoincided with the MD direction at the time of producing thefiber-reinforced plastic, and a bending test specimen in which thelongitudinal direction coincided with the TD direction.

In regard to the evaluation of the flexural strength ratio σ_(A)/σ_(B),a sample in which isotropy was obviously poor, and the flexural strengthratio σ_(A)/σ_(B) was 5 or more, or 0.2 or less, was rated as “x”.

[Evaluation of Fluidity]

A plate-shaped material which measured 78 mm in width and 78 mm inlength was cut out from a fiber-reinforced plastic thus obtained. Pluralsheets of the plate-shaped material were stacked so as to obtain athickness of about 4 mm, and the laminate was heated for 10 minutes at230° C. using a mini test press (manufactured by Toyo Seiki Seisaku-sho,Ltd., product name: MP-2FH), and then was pressed for 60 seconds underthe conditions of 145° C. and 5 MPa. The initial thickness h_(A) (mm)obtained before press molding and the final thickness h_(B) (mm)obtained after press molding were measured, and fluidity was evaluatedbased on the ratio h_(A)/h_(B) obtained by dividing the initialthickness by the final thickness.

In regard to the evaluation of fluidity, a sample in which the ratioh_(A)/h_(B) was less than 1.1 was rated as “x”. Meanwhile, there is asituation that the plate-shaped material increases in thickness at thetime of heating due to the residual stress of the reinforcing fibers inthe plate-shaped material, which is referred to as spring-back. The casein which the plate-shaped material did not restore the originalthickness even if the plate-shaped material was press molded afterundergoing spring-back with heating for 10 minutes, was also rated as“x”.

[Evaluation of Pf and Ec]

The values of pf and ec were respectively measured according to themeasurement method for pf and the measurement method for ec describedabove. An X-ray diffraction analysis was carried out using an X-raydiffraction apparatus (manufactured by Rigaku Co., Ltd., TTR-III)equipped with a fiber sample stage, by mounting a measurement sample onthe stage and using a Cu target. Specifically, while the measurementsample was irradiated with X-radiation from the upper side, themeasurement sample was rotated about the thickness direction as an axis,and diffracted X-radiation was detected with a detector disposed at adiffraction angle 2θ=24.5°. As a standard sample, a sample having a Vfof 35% by volume was used.

[Evaluation of Dp]

A sample specimen which measured 3 cm on each side was cut out from acarbon fiber-reinforced plastic, and was embedded in TECHNOVIT 4000manufactured by Heraeus Kulzer GmbH. After being cured, TECHNOVIT 4000was polished so that a cross-section of the sample specimen was exposed,and TECHNOVIT 4000 was subjected to a mirror surface treatment.

Next, a cross-sectional photograph of the sample specimen was takenunder the following conditions.

(Photographing Conditions)

Apparatus: Industrial optical microscope BX51M manufactured by OlympusCorporation.

Lens magnification: 500 times

Imaging dot pitch: 0.17 μm

In the cross-sectional photograph thus obtained, an area correspondingto the range of 2 mm in the thickness direction in the cross-section ofa sample specimen and 0.5 mm in a direction orthogonal to the thicknessdirection, was designated as a processing object image. The value of dpwas calculated by the method for measuring dp as described above, usingsoftware WIN-ROOF as an image editing software program. Calculation ofdp was performed at five sites in a cross-section of each samplespecimen, and the average value was determined.

Production Example 1: Production of Prepreg Substrate-1

Carbon fibers (PYROFIL TR50S manufactured by Mitsubishi Rayon Co., Ltd.,carbon fiber diameter: 7 μm) were arranged in parallel in one directionand in a planar form, and thus a fiber sheet having a basis weight of 72g/m² was obtained. Both surfaces of this fiber sheet were interposedbetween films each formed from an acid-modified polypropylene resin(MODIC P958V manufactured by Mitsubishi Chemical Corp., MFR50) andhaving a basis weight of 36 g/m². These were subjected to heating andpressing by passing them through between calender rolls several times,and the fiber sheet was impregnated with the resin. Thus, prepregsubstrate-1 having a fiber volume percentage content (Vf) of 33% byvolume and a thickness of 120 μm was produced.

Production Example 2: Production of Prepreg Substrate-2

Carbon fibers (PYROFIL TR50S manufactured by Mitsubishi Rayon Co., Ltd.)were arranged in parallel in one direction and in a planar form, andthus a fiber sheet having a basis weight of 37 g/m² was obtained. Bothsurfaces of this fiber sheet were interposed between films each formedfrom an acid-modified polypropylene resin (MODIC P958V manufactured byMitsubishi Chemical Corp., MFR50) and having a basis weight of 45 g/m².These were subjected to heating and pressing by passing them throughbetween calender rolls several times, and the fiber sheet wasimpregnated with the resin. Thus, prepreg substrate-2 having a fibervolume percentage content (Vf) of 17% by volume and a thickness of 120μm was produced.

Production Example 3: Production of Prepreg Substrate-3

Carbon fibers (PYROFIL TR50S manufactured by Mitsubishi Rayon Co., Ltd.)were arranged in parallel in one direction and in a planar form, andthus a fiber sheet having a basis weight of 105 g/m² was obtained. Bothsurfaces of this fiber sheet were interposed between films each formedfrom an acid-modified polypropylene resin (MODIC P958V manufactured byMitsubishi Chemical Corp., MFR50) and having a basis weight of 27 g/m².These were subjected to heating and pressing by passing them throughbetween calender rolls several times, and the fiber sheet wasimpregnated with the resin. Thus, prepreg substrate-3 having a fibervolume percentage content (Vf) of 49% by volume and a thickness of 120μm was produced.

Example 1

Rectangular-shaped prepreg substrate sheets each having a size of 220 mm(0°-direction with respect to the fiber axis)×900 mm (90°-direction withrespect to the fiber axis) were cut out from the prepreg substrate-1obtained in Production Example 1. An incision-inserted prepreg substratewas obtained by inserting slits having a depth that would cut thereinforcing fibers into the cut prepreg substrate, using a cuttingplotter (L-2500 cutting plotter manufactured by Laserck Corp.), suchthat the absolute value of the angle ϕ formed by the fiber axes of thereinforcing fibers was 45°, and the fiber length L of the reinforcingfibers was 25 mm. Eight sheets of the incision-inserted prepregsubstrate were laminated such that the fiber axes of the reinforcingfibers were in the same direction, and thus a prepreg laminate wasobtained. The thickness of the prepreg laminate was 1.0 mm.

As a pressing apparatus, a double belt-type heat press machine such asillustrated in FIG. 2, which included two rows of press rolls, the shaftdirection of which was coincident with a direction orthogonal to thetravel direction of the material (A), and the upper and lower belts weredriven at a rate of 1.0 m/min, was used. Furthermore, the prepreglaminate was introduced into the double belt-type heat press machinesuch that the angle θ formed by the fiber axial direction of thereinforcing fibers in each prepreg substrate-1 with respect to theorthogonal direction described above would be 0°. In the doublebelt-type heat press machine, the prepreg laminate was heated by tworows of press rolls under the conditions of a roll temperature of 270°C. and a linear pressure of 10.7 N/m, and the prepreg laminate waspressed in a state in which the thermoplastic resin was melted.Subsequently, the prepreg laminate was passed through a 1.5-m longcooling section equipped with one row of warm water rolls under theconditions of a roll temperature of 30° C. and a linear pressure of 2.5N/m, and the thermoplastic resin was solidified. Thus, afiber-reinforced plastic was obtained. Meanwhile, the travel speed ofthe prepreg laminate was the same as the driving speed of the belt.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance. Furthermore, the ratio h_(A)/h_(B) was 1.5, and thefiber-reinforced plastic had satisfactory fluidity.

Example 2

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that 16 sheets of the incision-inserted prepreg substrate werelaminated such that the fiber axes of the reinforcing fibers were in thesame direction, and thus a prepreg laminate having a thickness of 1.9 mmwas obtained.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 3

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the absolute value of the angle ϕ formed by the fiberaxial direction of the reinforcing fibers and the direction of slits wasset to 30°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 4

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the absolute value of the angle ϕ formed by the fiberaxial direction of the reinforcing fibers and the direction of slits wasset to 60°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 5

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the absolute value of the angle ϕ formed by the fiberaxial direction of the reinforcing fibers and the direction of slits wasset to 60°, 4 sheets of the incision-inserted prepreg substrate werelaminated such that the fiber axes of the reinforcing fibers were in thesame direction, and a prepreg laminate having a thickness of 0.5 mm wasobtained.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation.

Example 6

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the absolute value of the angle ϕ formed by the fiberaxial direction of the reinforcing fibers and the direction of slits wasset to 60°, 16 sheets of the incision-inserted prepreg substrate werelaminated such that the fiber axes of the reinforcing fibers were in thesame direction, and a prepreg laminate having a thickness of 1.9 mm wasobtained.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 7

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the absolute value of the angle ϕ formed by the fiberaxial direction of the reinforcing fibers and the direction of slits wasset to 90°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 8

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the fiber length L of the reinforcing fibers was adjustedto 12.5 mm.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 1. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 9

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the travel speed of the prepreg laminate was set to 0.5m/min. The travel speed of the prepreg laminate was reduced to a halfcompared to Example 1, and this implies that the heating and pressingtime was substantially doubled.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance. In addition, the flexural strength ratio σ_(A)/σ_(B) was0.83, and the mechanical properties of the fiber-reinforced plasticbecame anisotropic.

Example 10

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the travel speed of the prepreg laminate was set to 2.0m/min. The travel speed of the prepreg laminate was doubled compared toExample 1, and this implies that the heating and pressing time wassubstantially reduced to a half.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance. In addition, the flexural strength ratio σ_(A)/σ_(B) was0.37, and the fiber-reinforced plastic was a material having mechanicalproperties that were specifically strong in one direction.

Example 11

An incision-inserted prepreg substrate was obtained in the same manneras in Example 1, except that rectangular-shaped prepreg substrate sheetseach having a size of 220 mm (30°-direction with respect to the fiberaxis)×900 mm (−75°-direction with respect to the fiber axis) were cutout from the prepreg substrate-1. Eight sheets of the incision-insertedprepreg substrate were laminated such that the fiber axes of thereinforcing fibers were in the same direction, and a prepreg laminatehaving a thickness of 1.0 mm was obtained.

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the prepreg laminate was introduced into a doublebelt-type heat press machine such that the angle θ would be 15°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. The fiber-reinforcedplastic had satisfactory mechanical properties, and also had lessvariation. Furthermore, the flexural strength ratio σ_(C)/σ_(D) was 0.5or higher, and the fiber-reinforced plastic had satisfactory heatresistance.

Example 12

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that 4 sheets of the incision-inserted prepreg substrate werelaminated such that the fiber axes of the reinforcing fibers were in thesame direction, and a prepreg laminate having a thickness of 0.5 mm wasobtained. The ratio h_(A)/h_(B) of the fiber-reinforced plastic was 1.5,and the fiber-reinforced plastic had satisfactory fluidity.

Next, plate pieces each measuring 298 mm on each side were cut out fromthe fiber-reinforced plastic thus obtained, and 4 sheets of the platepieces were laminated. The laminate was disposed inside a pillbox moldwhich measured 300 mm on each side and 15 mm in depth, the mold washeated to 200° C., and the laminate was heated and pressed for 2 minuteswith a multistage press machine (compression molding machinemanufactured by Shinto Metal Industries Corp., product name: SFA-50HH0)at a pressure of 0.1 MPa using board faces at 200° C. Subsequently, thelaminate was cooled to room temperature at the same pressure, and thus aplate-shaped fiber-reinforced plastic having a thickness of 2 mm wasobtained. For the fiber-reinforced plastic having a thickness of 2 mmthus obtained, pf, ec, and dp were measured.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic having a thickness of 2 mm are presented inTable 3. The fiber-reinforced plastic had satisfactory mechanicalproperties, and also had less variation. Furthermore, the flexuralstrength ratio σ_(C)/σ_(D) was 0.5 or higher, and the fiber-reinforcedplastic had satisfactory heat resistance. Furthermore, the ratioh_(A)/h_(B) was 1.5, and the fiber-reinforced plastic had satisfactoryfluidity.

Example 13

A fiber-reinforced plastic plate having a thickness of 2 mm was obtainedin the same manner as in Example 12, except that the prepreg substrate-2was used instead of the prepreg substrate-1.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic having a thickness of 2 mm are presented inTable 3. The fiber-reinforced plastic had satisfactory mechanicalproperties, and also had less variation. Furthermore, the flexuralstrength ratio σ_(C)/σ_(D) was 0.5 or higher, and the fiber-reinforcedplastic had satisfactory heat resistance. Furthermore, the ratioh_(A)/h_(B) was 2.2, and the fiber-reinforced plastic had satisfactoryfluidity.

Comparative Example 1

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that slits were not inserted into the prepreg substrate cutout from the prepreg substrate-1.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. In thefiber-reinforced plastic, the mechanical properties obviously lackedisotropy and were not well controlled. The fiber-reinforced plastic alsohad low fluidity.

Comparative Example 2

An incision-inserted prepreg substrate was obtained in the same manneras in Example 1, except that rectangular-shaped prepreg substrate sheetseach having a size of 220 mm (30°-direction with respect to the fiberaxis)×900 mm (−60°-direction with respect to the fiber axis) were cutout from the prepreg substrate-1. Eight sheets of the incision-insertedprepreg substrate were laminated such that the fiber axes of thereinforcing fibers were in the same direction, and a prepreg laminatehaving a thickness of 1.0 mm was obtained.

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the prepreg laminate was introduced into a doublebelt-type heat press machine such that the angle θ would be 30°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. In thefiber-reinforced plastic, the mechanical properties obviously lackedisotropy and were not well controlled. Also, the fiber-reinforcedplastic had low fluidity.

Comparative Example 3

An incision-inserted prepreg substrate was obtained in the same manneras in Example 1, except that rectangular-shaped prepreg substrate sheetseach having a size of 220 mm (45°-direction with respect to the fiberaxis)×900 mm (−45°-direction with respect to the fiber axis) were cutout from the prepreg substrate-1. Eight sheets of the incision-insertedprepreg substrate were laminated such that the fiber axes of thereinforcing fibers were in the same direction, and a prepreg laminatehaving a thickness of 1.0 mm was obtained.

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the prepreg laminate was introduced into a doublebelt-type heat press machine such that the angle θ would be 45°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. In thefiber-reinforced plastic, the mechanical properties obviously lackedisotropy and were not well controlled. Also, the fiber-reinforcedplastic had low fluidity.

Comparative Example 4

An incision-inserted prepreg substrate was obtained in the same manneras in Example 1, except that rectangular-shaped prepreg substrate sheetseach having a size of 220 mm (90°-direction with respect to the fiberaxis)×900 mm (0°-direction with respect to the fiber axis) were cut outfrom the prepreg substrate-1. Eight sheets of the incision-insertedprepreg substrate were laminated such that the fiber axes of thereinforcing fibers were in the same direction, and a prepreg laminatehaving a thickness of 1.0 mm was obtained.

A fiber-reinforced plastic was obtained in the same manner as in Example1, except that the prepreg laminate was introduced into a doublebelt-type heat press machine such that the angle θ would be 60°.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 2. In thefiber-reinforced plastic, the mechanical properties obviously lackedisotropy and were not well controlled. Also, the fiber-reinforcedplastic had low fluidity.

Comparative Example 5

Band-shaped slits having a width of 15.0 mm were inserted into theprepreg substrate-3 obtained in Production Example 3, and then theprepreg substrate-3 was continuously cut into a length of 25.0 mm usinga guillotine type cutting machine. Thus, chopped strand prepreg sheetseach having a fiber length of 25.0 mm was obtained. 244 g of the choppedstrand prepreg sheets thus obtained were weighed, and the chopped strandprepreg sheets were freely dropped sheet by sheet from a place at aheight of 30 cm into a pillbox mold measuring 300 mm on each side and 15mm in depth so as to laminate the sheets such that the fiber orientationwas random.

The pillbox mold in which the chopped strand prepreg sheets werelaminated was heated to 200° C., and then the prepreg sheets were heatedand pressed for 2 minutes using a multistage press machine (compressionmolding machine manufactured by Shinto Metal Industries Corp., productname: SFA-50HH0) at a pressure of 0.1 MPa using board faces at 200° C.Subsequently, the laminate was cooled to room temperature at the samepressure, and thus a plate-shaped fiber-reinforced plastic having athickness of 2 mm was obtained. For the fiber-reinforced plastic havinga thickness of 2 mm thus obtained, pf, ec, and dp were measured.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 3. The fiber-reinforcedplastic had large variation in the mechanical properties, and lackedheat resistance.

Comparative Example 6

An incision-inserted prepreg substrate was obtained by cutting outprepreg substrate sheets each measuring 300 mm on each side from theprepreg substrate-1, and inserting linear-shaped slits at a constantinterval, using a cutting plotter (L-2500 cutting plotter manufacturedby Laserck Corp.). Slit processing was performed in a part that was onthe inner side than the parts extending to 5 mm from the circumferencein the prepreg substrate, such that the fiber length of the carbonfibers was 25.0 mm, the length of the slits was 20.0 mm, and the angle ϕformed by the fiber axes of the reinforcing fibers and the slits was30°. Sixteen sheets of the incision-inserted prepreg substrate werelaminated such that the fiber directions of the variousincision-inserted prepreg substrate sheets would be0°/45°/90°/−45°/−45°/90°/45°/0°/0°/45°/90°/−45°/−45°/90°/45°/0° from theabove. The laminate incision-inserted prepreg substrate sheets were spotwelded with an ultrasonic welding machine (manufactured by EmersonJapan, Ltd., product name: 2000LPt), and thereby a pseudo-isotropic([0/45/90/−45]s2) prepreg laminate was produced.

The prepreg laminate was disposed inside a pillbox mold which measured300 mm on each side and 15 mm in depth, the mold was heated to 200° C.,and then the prepreg laminate was heated and pressed for 2 minutes usinga multistage press machine (compression molding machine manufactured byShinto Metal Industries, Ltd., product name: SFA-50HH0) at a pressure of0.2 MPa using board faces at 200° C. Subsequently, the laminate wascooled to room temperature at the same pressure, and thus a plate-shapedfiber-reinforced plastic having a thickness of 2 mm was obtained. Forthe fiber-reinforced plastic having a thickness of 2 mm thus obtained,pf, ec, and dp were measured.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 3. The fiber-reinforcedplastic had inferior heat resistance.

Comparative Example 7

Carbon fibers (PYROFIL TR 50S manufactured by Mitsubishi Rayon Co.,Ltd.) were cut into 6 mm using a rotary cutter, and thereby choppedcarbon fibers were obtained. Similarly, fibers formed from anacid-modified polypropylene resin (MODIC P958V manufactured byMitsubishi Chemical Corp., MFR 50) were cut into 3 mm, and choppedpolypropylene fibers were obtained. 0.74 kg of the chopped polypropylenefibers was introduced into 110 kg of an aqueous solution of polyethyleneoxide at a mass concentration of 0.12%, and the fibers were sufficientlystirred using a stirrer. Subsequently, 0.37 kg of the chopped carbonfibers was introduced therein, the mixture was stirred for 10 seconds,and thus a dispersion liquid was obtained. The dispersion liquid thusobtained was flowed into a mesh frame which measured 100 cm on eachside, and the aqueous solution of polyethylene oxide was filtered.Subsequently, moisture was completely eliminated in a dryer at 120° C.,and thus a prepreg substrate having a fiber volume percentage content of20% by volume (fiber mass percentage content: 33% by mass) and a basisweight of 1.11 kg/m² was obtained. The prepreg substrate thus obtainedwas cut out into sheets which measured 30 cm on each side, and twosheets thereof were superposed to obtain a prepreg laminate. The prepreglaminate was disposed inside a pillbox mold which measured 300 mm oneach side and 15 mm in depth, the mold was heated to 200° C., and thenthe prepreg laminate was heated and pressed for 2 minutes using amultistage press machine (compression molding machine manufactured byShinto Metal Industries, Ltd., product name: SFA-50HH0) at a pressure of0.2 MPa using board faces at 200° C. Subsequently, the laminate wascooled to room temperature at the same pressure, and thus a plate-shapedfiber-reinforced plastic having a thickness of 2 mm was obtained. Forthe fiber-reinforced plastic having a thickness of 2 mm thus obtained,pf, ec, and dp were measured.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 3. The fiber-reinforcedplastic had inferior fluidity.

Comparative Example 8

Chopped carbon fibers and chopped polypropylene fibers were obtained inthe same manner as in Comparative Example 7. 0.63 kg of the choppedpolypropylene fibers was introduced into 115 kg of an aqueous solutionof polyethylene oxide at a mass concentration of 0.12%, and the mixturewas sufficiently stirred using a stirrer. Subsequently, 0.54 kg of thechopped carbon fibers was introduced therein, the mixture was stirredfor 10 seconds, and a dispersion liquid was obtained. The dispersionliquid thus obtained was flowed into a mesh frame which measured 100 cmon each side, and the aqueous solution of polyethylene oxide wasfiltered. Subsequently, moisture was completely eliminated in a dryer at120° C., and thus a prepreg substrate having a fiber volume percentagecontent of 30% by volume (fiber mass percentage content: 46% by mass)and a basis weight of 1.17 kg/m² was obtained. The prepreg substratethus obtained was cut out into sheets which measured 30 cm on each side,and two sheets thereof were superposed to obtain a prepreg laminate. Aplate-shaped fiber-reinforced plastic having a thickness of 2 mm wasobtained in the same manner as in Comparative Example 7, using theprepreg laminate.

The results obtained by evaluating the mechanical properties of thefiber-reinforced plastic are presented in Table 3. The fiber-reinforcedplastic had inferior fluidity.

TABLE 1 Example 1 2 3 4 5 6 7 8 Slit-inserted prepreg Angle ϕ [°] 45 4530 60 60 60 90 45 Fiber length L [mm] 25 25 25 25 25 25 25 12.5 Prepreglaminate Number of laminations [sheets] 8 16 8 8 4 16 8 8 Thickness (mm)1 1.9 1 1 0.5 1.9 1 1 Pressing conditions Angle θ [°] 0 0 0 0 0 0 0 0Travel speed of laminate [m/min] 1 1 1 1 1 1 1 1 Flexural strength RoomAverage value [MPa] 251 209 352 262 303 212 329 194 (MD direction)temperature CV value [%] 4.2 8.2 2.2 6.5 8.4 9.9 7.3 3.4 80° C. Averagevalue [MPa] 157 109 209 162 — 134 161 112 CV value [%] 8.3 9.9 1.8 3.6 —6.5 7.8 3.1 Flexural strength Room Average value [MPa] 393 349 450 402449 371 339 322 (TD direction) temperature CV value [%] 5.8 4.2 6.8 5.18.3 3.2 8.5 5.6 80° C. Average value [MPa] 207 188 214 254 — 201 194 179CV value [%] 8.0 9.4 2.7 8.1 — 2.0 5.2 6.0 Flexural strength ratioσ_(A)/σ_(B) 0.64 0.60 0.78 0.65 0.67 0.57 0.97 0.60 Flexural strengthratio σ_(C)/σ_(D) 0.58 0.53 0.53 0.63 — 0.59 0.53 0.57 Fluidity [times]1.5 — — — — — — —

TABLE 2 Example Comparative Example 9 10 11 12 1 2 3 4 Slit-insertedprepreg Angle ϕ [°] 45 45 45 45 No 45 45 45 Fiber length L [mm] 25 25 2525 slits 25 25 25 Prepreg laminate Number of laminations [sheets] 8 8 84 8 8 8 8 Thickness (mm) 1 1 1 0.5 1 1 1 1 Pressing conditions Angle θ[°] 0 0 15 0 0 30 45 60 Travel speed of laminate [m/min] 0.5 2 1 1 1 1 11 Flexural strength Room Average value [MPa] 380 152 199 — — — — — (MDdirection) temperature CV value [%] 3.3 8.0 10.2 — — — — — 80° C.Average value [MPa] 226 101 124 — — — — — CV value [%] 21.6 6.1 11.1 — —— — — Flexural strength Room Average value [MPa] 457 413 360 — — — — —(TD direction) temperature CV value [%] 0.9 0.8 9.8 — — — — — 80° C.Average value [MPa] 261 236 188 — — — — — CV value [%] 7.9 6.9 8.0 — — —— — Flexural strength ratio σ_(A)/σ_(B) 0.83 0.37 0.55 — X X X XFlexural strength ratio σ_(C)/σ_(D) 0.58 0.62 0.57 — — — — — Fluidity[times] — — — 1.50 X — — —

TABLE 3 Example Comparative Example 12 13 5 6 7 8 Fiber volumepercentage content (Vf) [vol %] 35 17 49 35 20 30 Fiber length L [mm] 2525 25 25 6 6 Degree of orientation pf 0.03 — 0.36 0.04 1.20 —Eccentricity coefficient ec (×10⁻⁵) 6.2 — 8.5 9.4 2.8 — Dispersionparameter dp 94 — 72 75 95 — Flexural strength Average value [MPa] 295235 218 268 253 301 (MD direction, room temperature) CV value [%] 4.89.8 23.5 4.5 6.7 5.1 Flexural strength Average value [MPa] 172 135 96129 154 177 (MD direction, 80° C.) CV value [%] 6.9 9.5 17.5 2.9 5.5 2.8Flexural strength Average value [MPa] 413 286 238 311 286 283 (TDdirection, room temperature) CV value [%] 6.2 9.6 15.1 5.1 6.7 4.6Flexural strength Average value [MPa] 257 173 107 149 166 156 (TDdirection, 80° C.) CV value [%] 4.2 4.5 17.1 7.4 6.6 0.4 Flexuralstrength ratio σ_(A)/σ_(B) 0.71 0.82 0.92 0.86 0.88 1.06 Flexuralstrength ratio σ_(C)/σ_(D) 0.60 0.59 0.44 0.48 0.59 0.57 Fluidity[times] 1.5 2.2 2.4 2.8 X X

INDUSTRIAL APPLICABILITY

The fiber-reinforced plastic obtainable by the production method of thepresent invention has excellent shapeability into complicatedthree-dimensional shapes such as a rib and a boss, and can be molded ina short time period. Furthermore, regarding this fiber-reinforcedplastic, a component part shaped therefrom has excellent mechanicalproperties that can be applied to structural materials, has lessvariation, and exhibits controllable isotropy or anisotropy. Therefore,the fiber-reinforced plastic is suitably used for aircraft members,automotive members, wind power generating windmill members, sportsgoods, and the like.

EXPLANATIONS OF LETTERS OR NUMERALS

-   -   1 DOUBLE BELT-TYPE HEAT PRESS MACHINE    -   10 PRESS ROLL    -   12 BELT    -   14 IR HEATER    -   16 WARM WATER ROLL    -   18 WINDING ROLL    -   20 DRIVING ROLL    -   22 DRIVEN ROLL    -   24 GUIDE ROLL    -   100 MATERIAL (A)    -   110 REINFORCING FIBER    -   120 FIBER-REINFORCED PLASTIC    -   X DIRECTION ORTHOGONAL TO TRAVEL DIRECTION OF MATERIAL (A)    -   Y DIRECTION OF FIBER AXIS OF REINFORCING FIBER

1. A method for producing a fiber-reinforced plastic, the methodcomprising: (i) pressing a material (A) with a pressing apparatus thatapplies pressure approximately uniformly in a direction orthogonal to atravel direction of the material (A); and (ii) cooling the material (A)that has been pressed by the pressing apparatus, and thereby obtaining afiber-reinforced plastic, wherein: the material (A) comprises a prepregsubstrate in which reinforcing fibers that are unidirectionally arrangedin parallel are impregnated with a matrix resin, and slits are formed soas to intersect the fiber axes; and the pressing (i) occurs such thatthe material (A) travels in one direction, with the angles θ formed byfiber axial directions of the reinforcing fibers of the prepregsubstrate with respect to an orthogonal direction being adjusted to −20°to 20°, in a state in which the material (A) is heated to a temperatureT that is higher than or equal to a melting point of the matrix resin,or is higher than or equal to a glass transition temperature if thematrix resin does not have a melting point.
 2. The method for producinga fiber-reinforced plastic according to claim 1, wherein the pressing(i) comprises (i−1) pressing the material (A) in a state of being heatedto the temperature T, while causing the material (A) to travel in onedirection, with a pressing apparatus which includes at least a pair ofpress rolls, with the shaft line direction of the rolls coinciding withthe orthogonal direction.
 3. The method for producing a fiber-reinforcedplastic according to claim 2, wherein the press rolls are heated rolls.4. The method for producing a fiber-reinforced plastic according toclaim 1, wherein the angle θ is adjusted to −5° to 5°.
 5. The method forproducing a fiber-reinforced plastic according to claim 1, wherein athickness of the material (A) is 0.25 mm to 6.0 mm.
 6. The method forproducing a fiber-reinforced plastic according to claim 1, wherein thematrix resin is a thermoplastic resin.
 7. The method for producing afiber-reinforced plastic according to claim 1, wherein the matrix resincomprises at least one selected from the group consisting of apolyolefin resin, a modified polypropylene resin, a polyamide resin, anda polycarbonate resin.
 8. The method for producing a fiber-reinforcedplastic according to claim 1, wherein a length L of the reinforcingfibers cut by slits in the prepreg substrate is 1 mm to 100 mm.
 9. Themethod for producing a fiber-reinforced plastic according to claim 2,wherein the pressing (i−1) occurs such that a double belt-type heatpress machine by which the material (A) is interposed between at leastone pair of belts and is heated while the material (A) is caused totravel so as to pass through between at least one pair of press rolls,and the material (A) is pressed with the at least one pair of pressrolls.
 10. A fiber-reinforced plastic, comprising carbon fibers and amatrix resin, wherein: a fiber length of the carbon fibers is 1 mm to100 mm; a degree of orientation pf of the carbon fibers in a directionthat orthogonally intersects a thickness direction is 0.001 to 0.8; andan eccentricity coefficient ec of an orientation profile of the carbonfibers in a plane that orthogonally intersects the thickness directionis 1×10⁻⁵ to 9×10⁻⁵.
 11. The fiber-reinforced plastic according to claim10, wherein a dispersion parameter dp of the carbon fibers in across-section in the thickness direction is 100 to
 80. 12. Thefiber-reinforced plastic according to claim 10, wherein the matrix resinis formed from a thermoplastic resin.
 13. The fiber-reinforced plasticaccording to claim 10, wherein a fiber volume percentage content of thecarbon fibers is 5% to 70% by volume.
 14. The fiber-reinforced plasticaccording to claim 10, wherein the fiber length of the carbon fibers is10 mm to 50 mm.